Additive manufacturing of metal matrix composites

Nartu, Mohan Sai Kiran Kumar Yadav; Agrawal, Priyanshi

doi:10.1016/j.matdes.2025.113609

Title: Additive manufacturing of metal matrix composites

Journal Article · Sat Jan 18 00:00:00 UTC 2025 · Materials & Design

DOI: https://doi.org/10.1016/j.matdes.2025.113609 · OSTI ID:2587269

Nartu, Mohan Sai Kiran Kumar Yadav ^[1];

^[2]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)
Idaho National Laboratory (INL), Idaho Falls, ID (United States)

Although Metal matrix composites (MMCs) are superior to most sought-after metallic alloys, their challenging fabricability has limited their widespread use in bulk-form applications. Among the many advanced fabrication techniques, Additive Manufacturing (AM), owing to its unique capabilities to produce near-net shapes, has drawn significant traction in the past two decades, especially for materials that are difficult to process using traditional methods. However, unlike pure metal/alloy systems, MMCs are highly sensitive to the processing conditions prevailing in AM techniques due to factors such as the high melting point of reinforcement particles and the potential for in-situ reactions. Therefore, it may be a while before metal matrix composites are commercially produced via AM. This review will discuss the current state-of-the-art design, fabricability, and performance of various additively manufactured MMCs. A particular focus will be on microstructural evolution and microstructure-property relationships. The most employed AM techniques, such as directed energy deposition, powder bed fusion, binder jetting, sheet lamination, and solid-state friction stir processing, are fundamentally different in terms of thermo-kinetics, forming the perspective for this review. A detailed comparison of microstructural evolution and process parameter optimization, including feedstock preparation methods and the role of machine learning and modeling among the different AM processes, is also presented. Finally, a critical evaluation of emerging AM technologies for MMCs is also provided, highlighting their potential advantages and challenges.

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Research Organization:: Idaho National Laboratory (INL), Idaho Falls, ID (United States); Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE Office of Nuclear Energy (NE)

Grant/Contract Number:: AC05-76RL01830; AC07-05ID14517

OSTI ID:: 2587269

Report Number(s):: INL/JOU-24-77351-Rev000; PNNL-SA-196895

Journal Information:: Materials & Design, Journal Name: Materials & Design Vol. 252; ISSN 0264-1275

Publisher:: Elsevier BVCopyright Statement

Country of Publication:: United States

Language:: English

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Additive Manufacturing of Customized Metallic Orthopedic Implants: Materials, Structures, and Surface Modifications Metals, Vol. 9, Issue 9 https://doi.org/10.3390/met9091004	journal	September 2019
Advancements in SiC-Reinforced Metal Matrix Composites for High-Performance Electronic Packaging: A Review of Thermo-Mechanical Properties and Future Trends Lai, Liyan; Niu, Bing; Bi, Yuxiao Micromachines, Vol. 14, Issue 8 https://doi.org/10.3390/mi14081491	journal	July 2023
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Microstructure and Mechanical Properties of TiB₂/ Al-Si Composites Fabricated by TIG Wire and Arc Additive Manufacturing Yang, Qing Feng; Xia, Cun Juan; Deng, Ya Qi Materials Science Forum, Vol. 944 https://doi.org/10.4028/www.scientific.net/MSF.944.64	journal	January 2019
Effect of Casting and Additive Manufacturing on the Microstructure and Mechanical Property of Al-Cu Composites Lei, Shuang; Deng, Ya Qi; Li, Xian Feng Materials Science Forum, Vol. 993 https://doi.org/10.4028/www.scientific.net/MSF.993.718	journal	May 2020
Microstructure, Worn Surface, Wear Assessment and Taguchi’s Approach of Titanium Alloy Hybrid Metal Matrix Composites for Automotive Applications Ramana Murty Naidu, S. C. V.; Kalidas, N.; Venkatachalam, Sivaraman SAE Technical Paper Series https://doi.org/10.4271/2023-01-5103	conference	February 2024
Investigation of Penetration Depth and Efficiency of Applied Heat Flux in a Directed Energy Deposition Process with Feeding of Ti-6Al-4V Wires Chua, Bih Lii; Lee, Ho Jin; Ahn, Dong Gyu Journal of the Korean Society for Precision Engineering, Vol. 35, Issue 2 https://doi.org/10.7736/KSPE.2018.35.2.211	journal	February 2018

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